Harsco Industrial MODU-FIRE FORCED DRAFT N750, Installation & Owner'S Manual

Page 1: ...100 Burson Street East Stroudsburg PA 18301 Telephone 570 476 7261 Facsimile 570 476 7247 www harscopk com C S A Design Certified Complies with ANSI Z21 13 CSA 4 9 Gas Fired Low Pressure Steam and Ho...

Page 2: ...3 9 Pre Start Check List 26 3 10 Safety Checks 27 3 11 Boiler Operating Control 28 3 12 Burner Adjustment 30 4 0 OPERATION 31 4 1 General 31 4 2 Lighting and Shut Down Procedures 31 5 0 MAINTENANCE 3...

Page 3: ...lier It is essential to read understand and follow the recommendations of this manual before installing operating or servicing this equipment Installation and service must be performed by a qualified...

Page 4: ...other operating characteristics not deliver heat to the desired location Additional equipment such as temperature sensors pumps flow switches balancing valves and check valves will be re quired for s...

Page 5: ...The safety labels shown above are affixed to your boiler Although the labels are of high quality they may be come dislodged or unreadable over time Contact Harsco Industrial Patterson Kelley toll fre...

Page 6: ...codes and standards including NFPA 54 ANSI Z223 1 and CSA B 149 Hazard from incorrect fuels Possible fire explosion overheating and damage Do not use any fuels except the design fuel for the unit Ove...

Page 7: ...nd component failure Do not attempt to adjust firing rate of the boi ler The firing rate must be adjusted only by factory trained person nel 2 5 3 Crush Hazards Lifting hazards Use properly rated lift...

Page 8: ...is not installed immediately it must be stored in a location adequately protected from the weather and freezing conditions preferably indoors If this is not possible then it should remain in the shipp...

Page 9: ...d installed gas cocks must be T handle type c piping of condensate shall conform to the State Plumbing Code and d refer to the Massachusetts supplement for further details 3 3 SETUP 3 3 1 Foundation P...

Page 10: ...earth ground green wire is re quired to avoid nuisance shutdowns It is also important that proper polarity be maintained The junction box at the rear of the boiler contains terminal strips for power...

Page 11: ...switch is in the remote position This circuit is energized by the boiler It has a 24VAC potential Devices connected to these terminals must be rated for 24VAC The remote local enable switch bypasses...

Page 12: ...s Canada CAN CSA B149 1 Installation Codes for Gas Burning Equipment STANDARDS UL 1738 Venting Systems for Gas Burning Appliances Categories II III and IV These codes and standards contain information...

Page 13: ...for combustion is derived directly from outdoors and all flue gases are discharged to the outdoors 3 5 1 2 Venting Materials for Flue Exhaust Systems MODU FIRE Forced Draft boilers are Category IV app...

Page 14: ...input capacity When combustion air is supplied from outside the building the boiler room shall be provided with one or two open ings to ensure adequate combustion air and proper ventilation When usin...

Page 15: ...Btu Hr 321 mm 2 kW up to and including 1 000 000 Btu Hr plus 1 sq in 14 000 Btu Hr 155 mm 2 kW in excess 1 000 000 Btu Hr This opening must be either located at or ducted to a point not more than 18 i...

Page 16: ...used with a heat actuated automatic vent damper All boiler venting systems should be designed by a qualified venting profes sional experienced in venting system design The information contained herein...

Page 17: ...por could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment 3 5 3 2 2 Direct Vent Sealed Combustion Systems The vent terminal shall be...

Page 18: ...this con nection may be reduced to 4 or 5 diameter The 1 500 000 Btu 2 000 000 Btu boilers have 8 OD connections for the vent If venting design permits this connection may be reduced to 6 diameter The...

Page 19: ...feet of the vent This is illustrated in the following diagram Reference NFPA 54 ANSI Z223 1 National Fuel Gas Code To prevent the possible re circulation of flue gases the vent designer must take into...

Page 20: ...led exhaust vent leading from the boiler and terminating outdoors Air flow through the system is maintained by the combustion air fan 3 5 5 1 Intake Duct Materials and Sizes The air intake duct can be...

Page 21: ...Close fireplace dampers 4 Place the appliance being inspected in operation Follow the lighting instructions Adjust the thermostat so that the appliance will operate continuously 5 Test for spillage a...

Page 22: ...must be made using a pipe compound that is certified resistant to the action of liquefied petroleum gases Do not use Teflon tape on gas line threads NOTICE Piping must be installed such that no pipin...

Page 23: ...810 2 2 067 5 17 10 3 2 750 1 900 1 520 1 300 1 150 950 800 2 1 2 2 469 6 16 12 3 4 350 3 000 2 400 2 050 1 850 1 500 1 280 3 3 068 7 67 15 3 7 700 5 300 4 300 3 700 3 250 2 650 2 280 4 4 026 10 1 20...

Page 24: ...o prevent gravity circulation of the boiler water during the cooling cycle 3 7 2 Boiler Water Connections Boiler Water Connections Make water connections as the application warrants or at a minimum as...

Page 25: ...ain codes or in certain installations Consult your local code for details Never install a valve that can isolate the low water cut off from the boiler 3 7 3 4 Drain Valve and Piping The boiler is not...

Page 26: ...r use and disposal 3 8 BURNER AND IGNITION SYSTEM 3 8 1 Inspection Inspect the burners to be sure nothing was damaged or knocked loose during shipment Inspect the main gas train and ignition assembly...

Page 27: ...to light 4 The main gas valve will not open because there is no power to the valve due to the disconnected wires Hence no flame will be established and the flame safeguard will not receive a flame si...

Page 28: ...rip the high gas pressure switch The switch should shut down the main burner The control will display HIGH GAS PRESSURE This is a manual reset error and the boiler should not start until the gas valve...

Page 29: ...TERS CONFIGURATION CASCADE and SERVICE menus The UP and DOWN buttons are used to position the arrow next to the desired option and the ENTER button is pushed to access that option 3 11 1 1 Configuring...

Page 30: ...utomatic air gas ratio valve This valve is adjusted at the factory to give 5 5 6 O2 at high fire and 7 5 7 9 O2 at low fire in the exhaust gas However the fuel air ratio should be checked using a comb...

Page 31: ...personnel to inspect the boiler and replace any part of the control sys tem and any gas control which has been exposed to water 4 2 1 Initial Lighting Procedures 1 Utilities Turn on electrical supply...

Page 32: ...LE Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing 5 1 1 Daily Observe operating tempera...

Page 33: ...shut Please see the manufacturer s recommendations on the relief valve tag 5 1 4 Annually In addition to the recommended monthly service 1 Inspect burner and ignition system Wash the burner do not scr...

Page 34: ...sconnect the air gas mixer sensing tubes Note these tubes are color coded and must be correctly reins talled 6 Remove the blower air gas mixer assembly from the top of the burner 7 Clean the blower va...

Page 35: ...wire plug to the blower the two air gas mixer sensing tubes the UV scanner and wires to the back pressure switch Before starting the boiler make sure to reconnect and tighten the gas union 4 Reinstal...

Page 36: ...wer is driven to the ignition speed 7 A trial for ignition begins The sequence of events is illustrated graphically below 8 After ignition the fan may be driven to low fire before the boiler is releas...

Page 37: ...estored LOW GAS PRESSURE will remain on the display panel A manual reset is required to restart the boiler provided that all other limits are satisfied 5 6 4 High Gas Pressure The high gas pressure sw...

Page 38: ...curs A manual reset of the programmer located inside the control panel is required 5 6 9 Flame Failure In the event of a flame failure the main fuel valves are de energized and a manual reset lockout...

Page 39: ...urge A20 EARLY FLAME Early Flame Flame detected before boiler gas valve opened during pre purge A30 HIGH GAS PRESSURE High Gas Pressure Error The gas pressure is too high and has tripped the HGPS A31...

Page 40: ...ame detected when no flame should be present E21 LOW FLOW ILK Low Water Flow or Open Inter lock Circuit E21 converts to A07 after 5 minutes E22 NO GROUND 60 HZ ERR No Ground error No ground connected...

Page 41: ...epresentative 6 1 1 Terminal Block Assignments High Voltage Circuit HV Terminal Number Label Description 1 L1 208 240 V Boiler Supply Power L1 230 VAC 1 ph 60 Hz 2 L2 208 240 V Boiler Supply Power L2...

Page 42: ...oor Temp Sensor Outdoor Temperature Sensor Circuit 8 9 DHW Stat or Sensor Domestic Hot Water Thermostat contact closure or Tem perature Sensor 10 11 Header Temp Sensor Header Temperature Sensor 12 13...

Page 43: ...NABLE DISABLE COM 1A COM 1B A TO A B TO B 10 G 1 2 3 4 5 6 7 8 12 13 14 15 16 17 18 19 20 21 11 0 10V 0V COM FLAME DETECTED RELAY MASTER ALARM RELAY CIRC PUMP RELAY 120V AC SWITCHED OUTPUT DHW PUMP RE...

Page 44: ...play Panel 8 Neutral Terminal Block 2 ENVI Main Board 9 ENVI Interface Board 3 Inverter Fuses 10 Air Switch 4 Blower Inverter Control 11 Ignition Transformer 5 On Off Switch 12 High Water Temp Limit 6...

Page 45: ...MODU FIRE Forced Draft Gas Fired Boiler 45 6 1 5 Main Control Panel Point to Point Left Side Alarm Flame Enable...

Page 46: ...MODU FIRE Forced Draft Gas Fired Boiler 46 6 1 6 Main Control Panel Point to Point Right Side...

Page 47: ...MODU FIRE Forced Draft Gas Fired Boiler 47 6 1 7 Junction Box Point to Point and Customer Connections...

Page 48: ...MODU FIRE Forced Draft Gas Fired Boiler 48 6 1 8 Customer Connections Details...

Page 49: ...Description 1 Main Gas Valve 2 Low Gas Pressure Switch 3 Leak Test Ports 4 Automatic Dual Gas Valve 5 Solenoid Coils 6 Gas Union 7 High Gas Pressure Switch 8 Secondary Gas Shutoff Valve 9 Air Gas Mix...

Page 50: ...iler 50 6 1 10 Blower Burner Ignition Assembly Mark Description 1 Burner Grid 2 Burner Gasket 3 Mounting Plate 4 Blower Gasket 5 Blower w Motor 6 Ignition Gasket 7 Ignition Electrode 8 UV Scanner 9 Ba...

Page 51: ...MODU FIRE Forced Draft Gas Fired Boiler 51 6 1 11 Heat Exchanger and Combustion Chamber Mark Description 1 Front Wrapper 2 Heat Exchanger 3 Gasket Set 4 Removable Top Head 4 3 2 1...

Page 52: ...t Gas Fired Boiler 52 6 1 12 Cabinet Assembly Mark Description 1 Front Door 2 Side Covers 3 Top Cover 4 Control Panel 5 Relief Valve 6 Flow Switch 7 Low Water Cutoff Switch optional 8 Air Inlet Assemb...

Page 53: ...ication F Any failure resulting from misuse modification not authorized by Seller in writing improper installation or lack of or improper maintenance G Equipment furnished by the owner either mounted...

Page 54: ...exits boiler High Low w c High Inlet Gas w c w c w c Low Oxygen O2 10 Electrical Supply Power L1 to L2 Volts Carbon Dioxide CO2 L1 to N Volts Carbon Monoxide CO ppm ppm Less than 1 volt between neutra...